Effect of atomizing rapid solidification spherical abrasive finishing on the surface quality of copper-nickel alloy

2021 ◽  
pp. 095440542110079
Author(s):  
Tonglei Cui ◽  
Guixiang Zhang ◽  
Yuntao Cui ◽  
Linzhi Jiang ◽  
Peixin Zhu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Nickel Alloy ◽  
Surface Quality ◽  
Process Parameters ◽  
Feeding Rate ◽  
Surface Hardness ◽  
Abrasive Finishing ◽  
Ni Alloy ◽  
Copper Nickel Alloy

To improve the surface roughness of Copper-Nickel alloy (Cu-Ni alloy) and explore the effect of magnetic abrasive finishing on the surface hardness and hydrophobicity of Cu-Ni alloy, the spherical magnetic abrasives are prepared by atomizing rapid solidification method. The effects of various process parameters on the surface quality of Cu-Ni alloy are explored, and the optimal process parameters of magnetic abrasive finishing of Cu-Ni alloy are obtained. The Neodymium-Iron-Boron permanent magnetic pole is used to grind the workpiece with XK7136C CNC milling machine. Three dimensional profilometer, metallographic microscope, and digital Vickers hardness tester are used to analyze the surface morphology of the workpiece. The hydrophilicity and hydrophobicity of the workpiece are measured by a contact angle goniometer. The effects of spindle speed, feeding rate, processing distance, and abrasive filling amount on the surface quality of workpiece are investigated by the orthogonal experiment and the single factor test. When the spindle speed is 1300 r/min, the feeding rate is 13 mm/min, the processing distance is 1.2 mm, and the abrasive filling amount is 2.0 g, the surface roughness of Cu-Ni alloy decreases from 0.212 to 0.023 μm and the hardness increases from 114 to 119.8 hv. Finally, the mirror effect of Cu-Ni alloy is achieved. When the optimal test parameters are used, the surface roughness of Cu-Ni alloy can be effectively reduced in a short time. The surface quality of the workpiece is improved, the surface hardness of the workpiece is affected to a certain extent, and the service life of the workpiece is prolonged.

The mechanism of process parameters influencing the AlSi10Mg side surface quality fabricated via laser powder bed fusion

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Shimin Dai ◽  
Hailong Liao ◽  
Haihong Zhu ◽  
Xiaoyan Zeng
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Laser Power ◽  
Side Surface ◽  
Laser Powder Bed Fusion ◽  
Scanning Velocity ◽  
Content Type ◽  
Powder Bed

Purpose For the laser powder bed fusion (L-PBF) technology, the side surface quality is essentially important for industrial applicated parts, such as the inner flow parts. Contour is generally adopted at the parts’ outline to enhance the side surface quality. However, the side surface roughness (Ra) is still larger than 10 microns even with contour in previous studies. The purpose of this paper is to study the influence of contour process parameters, laser power and scanning velocity on the side surface quality of the AlSi10Mg sample. Design/methodology/approach Using L-PBF technology to manufacture AlSi10Mg samples under different contour process parameters, use a laser confocal microscope to capture the surface information of the samples, and obtain the surface roughness Ra and the maximum surface height Rz of each sample after analysis and processing. Findings The results show that the side surface roughness decreases with the increase of the laser power at the fixed scanning velocity of 1,000 mm/s, the side surface roughness Ra stays within the error range as the contour velocity increases. It is found that the Ra increases with the scanning velocity increasing and the greater the laser power with the greater Ra increases when the laser power of contour process parameters is 300 W, 350 W and 400 W. The Rz maintain growth with the contour scanning velocity increasing at constant laser power. The continuous uniform contour covers the pores in the molten pool of the sample edge and thus increase the density of the sample. Two mechanisms named “Active adhesion” and “Passive adhesion” cause sticky powder. Originality/value Formation of a uniform and even contour track is key to obtain the good side surface quality. The side surface quality is determined by the uniformity and stability of the contour track when the layer thickness is fixed. These research results can provide helpful guidance to improve the surface quality of L-PBF manufactured parts.

scholarly journals Influence of Ultrasonic Burnishing Technique on Surface Quality and Change in the Dimensions of Metal Shafts

2014 ◽  
Vol 2014 ◽  
pp. 1-8 ◽  
Author(s):  
Juha Huuki ◽  
Mikael Hornborg ◽  
Jermu Juntunen
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Hardness ◽  
Modern Method ◽  
Processing Times ◽  
Good Surface ◽  
Rotating Shafts ◽  
Mechanical Surface ◽  
Reduced Surface

This paper presents ultrasonic burnishing as a mechanical surface treatment for improving the quality of rotating shafts. Ultrasonic burnishing is a modern method for finishing workpieces to produce a good surface quality. This process improves the surface quality and increases the surface hardness of the workpiece, and the surface roughness of the workpiece improves. As a result, wear resistance and fatigue life increase. Furthermore, these improvements are achieved without expensive equipment or long processing times. In this paper the influence of the ultraburnishing technique on the change in diameter and its effects on the out-of-roundness of rotating shafts are investigated. This paper also takes a look at the magnitudes of the improvement of the surface roughness as a result of using ultrasonic burnishing. Three different materials, aluminium, 34-CrNiMo6 tempering steel, and S355J2 structural steel, are examined. The results showed that ultrasonic burnishing is a treatment that improves the quality of components. Ultrasonic burnishing also has a reducing effect on the final diameter and out-of-roundness and increases the hardness of the workpiece. It can also be stated that the material of the workpiece does not have a significant effect on the magnitude of the reduced surface roughness values.

scholarly journals Optimising the process parameters of selective laser melting for the fabrication of Ti6Al4V alloy

2018 ◽  
Vol 24 (1) ◽  
pp. 150-159 ◽  
Author(s):  
Zhonghua Li ◽  
Ibrahim Kucukkoc ◽  
David Z. Zhang ◽  
Fei Liu
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
High Surface ◽  
Optimum Process ◽  
Laser Melting ◽  
Vertical Side ◽  
Content Type

Purpose Surface roughness is an important evaluation index for industrial components, and it strongly depends on the processing parameters for selective laser molten Ti6Al4V parts. This paper aims to obtain an optimum selective laser melting (SLM) parameter set to improve the surface roughness of Ti6Al4V samples. Design/methodology/approach A response surface methodology (RSM)-based approach is proposed to improve the surface quality of selective laser molten Ti6Al4V parts and understand the relationship between the SLM process parameters and the surface roughness. The main SLM parameters (i.e. laser power, scan speed and hatch spacing) are optimized, and Ti6Al4V parts are manufactured by the SLM technology with no post processes. Findings Optimum process parameters were obtained using the RSM method to minimise the roughness of the top and vertical side surfaces. Obtained parameter sets were evaluated based on their productivity and surface quality performance. The validation tests have been performed, and the results verified the effectivity of the proposed technique. It was also shown that the top and vertical sides must be handled together to obtain better top surface quality. Practical implications The obtained optimum SLM parameter set can be used in the manufacturing of Ti6Al4V components with high surface roughness requirement. Originality/value RSM is used to analyse and determine the optimal combination of SLM parameters with the aim of improving the surface roughness quality of Ti6Al4V components, for the first time in the literature. Also, this is the first study which aims to simultaneously optimise the surface quality of top and vertical sides of titanium alloys.

scholarly journals Influence of High-Productivity Process Parameters on the Surface Quality and Residual Stress State of AISI 316L Components Produced by Directed Energy Deposition

2021 ◽  
Author(s):  
Gabriele Piscopo ◽  
Alessandro Salmi ◽  
Eleonora Atzeni
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Surface Quality ◽  
Process Parameters ◽  
Energy Deposition ◽  
Industrial Applications ◽  
High Productivity ◽  
Directed Energy Deposition ◽  
Productivity Process ◽  
Directed Energy

AbstractThe production of large components is one of the most powerful applications of laser powder-directed energy deposition (LP-DED) processes. High productivity could be achieved, when focusing on industrial applications, by selecting the proper process parameters. However, it is of crucial importance to understand the strategies that are necessary to increase productivity while maintaining the overall part quality and minimizing the need for post-processing. In this paper, an analysis of the dimensional deviations, surface roughness and subsurface residual stresses of samples produced by LP-DED is described as a function of the applied energy input. The aim of this work is to analyze the effects of high-productivity process parameters on the surface quality and the mechanical characteristics of the samples. The obtained results show that the analyzed process parameters affect the dimensional deviations and the residual stresses, but have a very little influence on surface roughness, which is instead dominated by the presence of unmelted particles.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

Observation in the Surface Roughness of Silicon Wafer during Semi-Fixed Abrasive Machining with Large Grains

2009 ◽  
Vol 69-70 ◽  
pp. 253-257
Author(s):  
Ping Zhao ◽  
Jia Jie Chen ◽  
Fan Yang ◽  
K.F. Tang ◽  
Ju Long Yuan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Silicon Wafer ◽  
Processing Parameters ◽  
Wafer Surface ◽  
Abrasive Machining ◽  
Fixed Abrasive ◽  
Is Failure ◽  
Better Than

Semi-fixed abrasive is a novel abrasive. It has a ‘trap’ effect on the hard large grains that can prevent defect effectively on the surface of the workpiece which is caused by large grains. In this paper, some relevant experiments towards silicon wafers are carried out under the different processing parameters on the semi-fixed abrasive plates, and 180# SiC is used as large grains. The processed workpieces’ surface roughness Rv are measured. The experimental results show that the surface quality of wafer will be worse because of higher load and faster rotating velocity. And it can make a conclusion that the higher proportion of bond of the plate, the weaker of the ‘trap’ effect it has. Furthermore the wet environment is better than dry for the wafer surface in machining. The practice shows that the ‘trap’ effect is failure when the workpiece is machined by abrasive plate which is 4.5wt% proportion of bond in dry lapping.

Ultraschallüberlagertes Trennschleifen von Faserverbundwerkstoffen*/Ultrasound abrasive cutting of fiber composites - Survey on the potential and mode of action

2016 ◽  
Vol 106 (01-02) ◽  
pp. 39-43
Author(s):  
Y. Babenko ◽  
T. Mayer ◽  
A. Gebhardt
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Mode Of Action ◽  
Fiber Composites ◽  
Cutting Process ◽  
Force Analysis ◽  
Abrasive Cutting

Dieser Fachartikel befasst sich mit der Untersuchung des Potentials der Ultraschallüberlagerung beim Trennschleifen moderner Faserverbundwerkstoffe. Es wurde eine Zerspankraftanalyse des Trennschleifprozesses am CFK-Werkstück mit variierenden Prozessparametern durchgeführt. Zudem wurden die Oberflächenqualitäten der Schnittkanten betrachtet.   The presented study describes the investigation of the potential of ultrasound abrasive cutting of modern fiber composites. A force analysis of the abrasive cutting process of CFRP was conducted, while the process parameters were varied. In addition, the surface quality of the machined workpieces was observed.

scholarly journals ANALYSIS OF THE SURFACE QUALITY OF PARTS PROCESSED BY SINGLE POINT INCREMENTAL FORMING

2016 ◽  
Vol 19 (3) ◽  
Author(s):  
CRINA RADU ◽  
EUGEN HERGHELEGIU ◽  
ION CRISTEA ◽  
CAROL SCHNAKOVSZKY
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Metal Sheets ◽  
Vertical Step ◽  
Tool Diameter ◽  
Aluminium Metal

<p>The aim of the current work was to analyse the influence of the process parameters (tool diameter, size of the vertical step of tool, feed rate and spindle speed) on the quality of the processed surface, expressed in terms of roughness and macrostructure in the case of parts processed by single point incremental forming. The analysis was made on A1050 aluminium metal sheets. The obtained results revealed that the process parameters influence differently the surface quality, the worst influence being exerted by the increase of the vertical step of tool. </p>

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